Wacker Neuson RD24-100 US User manual

Operating manual

Tandem roller / Combination

roller

RD 24 US / RD 28 US

Roller type RD 24 US / RD 28 US

Issue 01

Document order number

Language

As from serial number:

5100028170

en-fr

WNCR0901KHAA00160

2

BA RD 24 US / RD 28 US en* 01*

Manufacturer

Wacker Neuson Produktion GmbH & Co. KG

Preußenstraße 41

80809 München

www.wackerneuson.com

Phone: +49-(0)89-354 02-0

Telefax: +49-(0)89-354 02-390

Original operating manual

created:

changed:

01.09.2015

01.10.2015

BA RD 24 US / RD 28 US en* 01*

3

This operating manual is valid for the following roller types:

TANDEM ROLLER RD 24-100 US

RD 24-100 O US

RD 28-120 US

RD 28-120 O US

COMBINATION ROLLER RD 24-100 C US

RD 28-120 C US

Table of contents

4

BA RD 24 US / RD 28 US en* 01*

TABLE OF CONTENTS

1 Foreword................................................................................................................ 10

1.00 Introduction....................................................................................................... 11

1.00.01 Preface for the operating manual........................................................................................ 11

1.00.02 Product information.............................................................................................................. 11

1.00.03 Guarantee.............................................................................................................................12

1.00.04 Modifications / reservations..................................................................................................12

1.00.05 Packaging and storage........................................................................................................ 12

1.00.06 Signs and symbols...............................................................................................................12

1.00.07 Signal words.........................................................................................................................14

1.01 Documentation.................................................................................................. 15

1.02 Use......................................................................................................................16

1.02.01 Intended use.........................................................................................................................16

1.02.02 Reasonably foreseeable misuse.......................................................................................... 17

1.02.03 Residual risks....................................................................................................................... 17

1.02.04 Climatic conditions............................................................................................................... 18

1.03 Environmental protection................................................................................ 19

1.04 Disposal............................................................................................................. 19

1.05 Type plate.......................................................................................................... 20

1.06 Noise and vibration requirements.................................................................. 23

1.07 Personnel...........................................................................................................24

1.07.01 Qualification and duties........................................................................................................24

1.08 General Safety Instructions.............................................................................26

1.09 Danger zone...................................................................................................... 27

1.10 Loading and Transporting............................................................................... 28

1.11 Stickers on the machine..................................................................................33

1.11.01 Warning labels......................................................................................................................33

1.11.02 Information sign....................................................................................................................35

2 Description.............................................................................................................39

2.00 Technical characteristics of the machine...................................................... 39

Table of contents

BA RD 24 US / RD 28 US en* 01*

5

2.01 General view of machine................................................................................. 40

2.01.01 Chassis / safety devices.......................................................................................................40

2.01.02 Control stand........................................................................................................................ 41

2.01.03 Drive unit / diesel engine..................................................................................................... 42

2.01.04 Hydraulic oil supply.............................................................................................................. 43

2.01.05 Electrical equipment............................................................................................................. 44

2.01.06 Drive..................................................................................................................................... 46

2.01.07 Steering system....................................................................................................................47

2.01.08 Water system........................................................................................................................47

2.01.09 Vibration / oscillation............................................................................................................ 48

2.02 General view of instruments and operating elements..................................49

2.02.01 Control stand........................................................................................................................ 49

2.02.02 Drive unit / diesel engine..................................................................................................... 53

2.02.03 Drive..................................................................................................................................... 54

3 Operation............................................................................................................... 55

3.00 Instruments and operating elements............................................................. 55

3.00.01 Indicators, displays...............................................................................................................55

3.00.02 Pilot lights............................................................................................................................. 55

3.00.03 Switch................................................................................................................................... 60

3.00.04 Sockets, lights...................................................................................................................... 66

3.00.05 Operation levers, adjustment handles................................................................................. 67

3.01 Prior to machine start...................................................................................... 71

3.02 Engine start....................................................................................................... 73

3.03 Driving................................................................................................................75

3.04 Driving with vibration / oscillation.................................................................. 78

3.05 Stopping, switching off engine, leaving machine......................................... 80

3.06 Operation monitoring....................................................................................... 82

3.06.01 Filling levels..........................................................................................................................82

3.06.02 Pilot lights............................................................................................................................. 82

3.07 Sprinkling...........................................................................................................83

3.08 *Additive sprinkling.......................................................................................... 85

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6

BA RD 24 US / RD 28 US en* 01*

3.09 Scraper...............................................................................................................86

3.09.01 Roller drum folding scraper - top......................................................................................... 86

3.09.02 Roller drum folding scraper - down..................................................................................... 87

3.09.03 Tyres scraper........................................................................................................................87

3.10 Track offset........................................................................................................88

3.11 Starting with jump leads..................................................................................89

3.12 Towing................................................................................................................90

4 Maintenance...........................................................................................................93

4.00 General maintenance instructions..................................................................93

4.00.01 Operation monitoring............................................................................................................93

4.00.02 Maintenance overview..........................................................................................................93

4.00.03 Running-in regulations......................................................................................................... 96

4.00.04 Important information about maintenance works.................................................................97

4.00.05 Safety strut........................................................................................................................... 99

4.00.06 Welding works on the machine..........................................................................................100

4.01 Chassis / safety features............................................................................... 101

4.01.01 General............................................................................................................................... 101

4.01.02 Checking the function of the parking brake....................................................................... 101

4.01.03 Checking the EMERGENCY STOP function..................................................................... 102

4.02 Drive unit - diesel engine.............................................................................. 104

4.02.01 General............................................................................................................................... 104

4.02.02 Maintenance points at the Diesel engine when changing oil.............................................105

4.02.03 Replacing filter cartridge for the fuel filter..........................................................................106

4.02.04 Changing the filter cartridge for the fuel pre-filter.............................................................. 107

4.02.05 Draining water separator....................................................................................................108

4.02.06 Checking and cleaning dust discharge valve.................................................................... 109

4.02.07 Checking and replacing the air filter.................................................................................. 109

4.02.08 Changing safety cartridge.................................................................................................. 110

4.02.09 Checking the radiator.........................................................................................................111

4.02.10 Checking coolant level....................................................................................................... 112

4.02.11 Changing coolant............................................................................................................... 113

4.03 Hydraulic oil supply....................................................................................... 115

4.03.01 General............................................................................................................................... 115

4.03.02 Checking hydraulic oil level............................................................................................... 115

4.03.03 Changing hydraulic oil and ventilation filter....................................................................... 116

4.03.04 Replacing filter insert of pressure filter for hydraulic system............................................. 117

Table of contents

BA RD 24 US / RD 28 US en* 01*

7

4.04 Drive................................................................................................................. 118

4.04.01 Check the drive lever......................................................................................................... 118

4.04.02 Checking the roller drum scraper...................................................................................... 118

4.04.03 Checking scraper tyre........................................................................................................ 119

4.04.04 Lubricate the scraper stop lever........................................................................................ 120

4.04.05 Checking the wheel nuts / wheel bolts for tightness..........................................................121

4.05 Checking the air pressure in the tyres.........................................................122

4.06 Changing the tyres......................................................................................... 123

4.07 Steering system.............................................................................................. 124

4.07.01 General............................................................................................................................... 124

4.07.02 Lubricating the pivoted bearing..........................................................................................124

4.07.03 Lubricating the steering cylinder bolt................................................................................. 125

4.08 Sprinkling.........................................................................................................126

4.08.01 General............................................................................................................................... 126

4.08.02 Cleaning the water sprinkling unit......................................................................................126

4.08.03 Cleaning the filter for sprinkling......................................................................................... 127

4.08.04 Cleaning the spay nozzles................................................................................................. 127

4.09 Vibration / oscillation......................................................................................128

4.09.01 Checking the damping elements........................................................................................128

4.09.02 Changing the toothed belt for the oscillation drive............................................................ 128

5 Tables................................................................................................................... 129

5.00 Technical data................................................................................................. 129

5.00.01 Engine oil............................................................................................................................129

5.00.02 Hydraulic oil........................................................................................................................130

5.00.03 Use of biohydraulic oil........................................................................................................130

5.00.04 Coolant treatment...............................................................................................................131

5.00.05 Fuel.....................................................................................................................................131

5.00.06 Overview of lubricant details.............................................................................................. 132

5.00.07 Starting torques.................................................................................................................. 133

5.01 Technical data................................................................................................. 134

5.01.01 RD 24-100 US....................................................................................................................134

5.01.02 RD 24-100 O US................................................................................................................136

5.01.03 RD 24-100 C US................................................................................................................138

5.01.04 RD 28-120 US....................................................................................................................140

5.01.05 RD 28-120 O US................................................................................................................142

5.01.06 RD 28-120 C US................................................................................................................144

Table of contents

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BA RD 24 US / RD 28 US en* 01*

5.02 Dimension sheet............................................................................................. 146

5.02.01 RD 24-100 US, RD 24-100 O US......................................................................................146

5.02.02 RD 24-100 C US................................................................................................................146

5.02.03 RD 28-120 US, RD 28-120 O US......................................................................................147

5.02.04 RD 28-120 C US................................................................................................................147

5.03 Fuses................................................................................................................148

5.04 Diagnostic Code............................................................................................. 149

6 Assembly Instructions and Auxiliary Devices................................................. 150

6.00 Instructions for installation and retrofitting................................................ 150

6.00.01 Safety device ROPS roll-over bar......................................................................................150

6.01 *Injection of antifreeze for the sprinkler...................................................... 152

6.01.01 Overview.............................................................................................................................152

6.01.02 Operation............................................................................................................................ 152

EC declaration of conformity

BA RD 24 US / RD 28 US en* 01*

9

EC DECLARATION OF CONFORMITY

616-02

Foreword

10

BA RD 24 US / RD 28 US en* 01*

1 FOREWORD

This operating manual contains information and procedures for the

safe operation and maintenance of your Wacker Neuson machine. In

the interest of your own safety and to prevent accidents, you should

carefully read through the safety information, familiarize yourself with it

and observe it at all times.

This operating manual is not a manual for extensive maintenance and

repair work. Such work should be carried out by Wacker Neuson service

or authorized specialists.

The safety of the operator was one of the most important aspects taken

into consideration when this machine was designed. Nevertheless,

improper use or incorrect maintenance can pose a risk. Please operate

and maintain your Wacker Neuson machine in accordance with the

instructions in this operator's manual. Your reward will be troublefree

operation and a high degree of availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson representative if you have any

questions concerning operation or maintenance.

No part of this publication may be reproduced in any form or by any

means, electronic or mechanical, including photocopying, without the

expressed written permission of Wacker Neuson.

Any type of reproduction, distribution or storage on data media of

any type and form not authorized by Wacker Neuson represents an

infringement of copyright and will be prosecuted.

We expressly reserve the right to make technical modifications – even

without special notice – which aim at further improving our machines or

their safety standards.

Foreword

Introduction

BA RD 24 US / RD 28 US en* 01*

11

1.00 Introduction

1.00.01 Preface for the operating manual

This chapter contains important instructions for the operating personnel

on how to operate the machine and to use this operating manual.

This operating manual helps you:

To become familiar with the machine.

To avoid malfunctions due to improper use.

Adhering to this operating manual:

Helps to avoid risks.

Increases the reliability when working on the construction site.

Increases the service life.

Reduces maintenance costs and downtimes.

It is absolutely necessary to adhere to this operating manual,

supplementary information and all regulations and provisions applying at

the building site (e.g. accident prevention regulations).

Maintenance and care of the diesel engine have to be performed

according to the instructions for the motor. The safety instructions must

be observed.

609-04

1.00.02 Product information

You have received a quality product from Wacker Neuson. All the

components of this machinehave been carefully inspected and tested. As

a result, they comply with the quality that you expect.

The reliability of the machine is preserved through correct use and careful

maintenance. This includes the use of the specified operating supply

items and the use of original Wacker Neuson spare parts.

Our representatives will help you to keep your roller in a perfect operating

condition.

After the warranty period, our representatives will also assist you with

advice and service. They will supply you with our original Wacker Neuson

spare parts which do not only meet the technical requirements but also

ensure exchangeability and quality.

The safety, operating and maintenance instructions given in this operating

manual are intended for the operating personnel. For this reason, always

keep it handy!

609-03

Foreword

Introduction

12

BA RD 24 US / RD 28 US en* 01*

1.00.03 Guarantee

No guarantee claims with:

Operating errors.

In the case the spare parts used are no original Wacker Neuson

spare parts.

In the case wrong operating supply items have been used.

In the case any additional devices have been refitted and/or installed

that have not been approved by Wacker Neuson.

In the case of deficient maintenance.

In the case of any processes that conflict with these operating

manual.

609-02

1.00.04 Modifications / reservations

We are committed to provide you with correct and updated operating

manual. However, we cannot guarantee the correctness of all data given.

To be able to keep pace with changing trends, it may be necessary to

amend or modify the product and/or its operating console without prior

notice. We assume no liability for malfunctions, downtimes and resulting

damage.

609-09

1.00.05 Packaging and storage

We have carefully packed our products to ensure proper protection in

transit. Please check both packaging and the goods yourselv for any

damage upon reception of your goods. In the case of damage, the

devices must not be put into operation. Damged cables and connections

are a safety risk and must not be used.

In such a case, please contact your supplier.

If the devices are not put into operation upon unpacking, they must be

protected against humidity and dirt.

609-10

1.00.06 Signs and symbols

The signs and symbols used in this operating manual are to help you use

this operating manual and the device in a safe and fast manner.

Note Informs about application hints and useful information. No

dangerous or harmful situation.

Enumeration Indicates a listing of issues or possibilities.

Operating steps Are listed according to their succession each starting from 1 for

each individual process.

Option Indicates special equipment which varies from the standard.

Directions Information on directions contained in these instructions such as left or

right and/or front or rear always refer to the directions of the machine

driving forwards.

Foreword

Introduction

BA RD 24 US / RD 28 US en* 01*

13

Cross-references Cross-references help you to find quickly sections in this operating

manual which supply you with additional important information. The

cross-reference shows you the page of the relevant section. The

abbreviation sqq. means "and the following pages".

Example: (see page 134 sqq.)

Positioning of illustrations The positions of illustrations are represented with letters and numbers.

The positions identified with letters in alphabetical order are only

explained in the corresponding text segment, beginning new for each

single figure. The positions marked with numbers apply to operating

elements, control units and switches. They are identical to the numbers

in the section Overview of Instruments and Operating Elements (see

page 49 sqq.). These numbers in squared brackets are used

as a reference in the description of the elements. Amongst others,

this ensures that important and additional information can be found

immediately and without difficulties in the descriptions of the elements.

The end of the positioning line is marked as dot or arrow. In the

illustration the dot marks a visible element and an arrow an invisible

element which is in arrow direction.

Example

Legend

[A] Driver [B] Engine compartment

Descriptive text

The drive lever [501] determines the direction of travel and the speed.

Using the lever [520] you can adjust the pretension of the attenuation

system to the driver's weight.

609-11

Foreword

Introduction

14

BA RD 24 US / RD 28 US en* 01*

1.00.07 Signal words

A signal word identifies a source of dangers and residual risks.

609-12

DANGER

Identifies immediate danger. If this risk is not prevented, this causes

death or severe personal injuries.

001-01

WARNING

Refers to situations that may be dangerous. If this situation is not

avoided, fatality or very serious injuries may be caused.

002-01

CAUTION

Refers to situations that may be dangerous. If this situation is not

avoided, minor or light injuries may be caused.

003-01

NOTICE

Refers to a situation that may cause property damage.

004-01

Foreword

Documentation

BA RD 24 US / RD 28 US en* 01*

15

1.01 Documentation

This operating manual is intended to make the operating personnel

familiar with basic work steps / activities of and with the machine.

The entire operating manual consists of:

Operating manual of the machine

Operating manual of the diesel engine

If necessary, additional information

The entire operating manual must always be available at the machine

and be accessible to the authorized operating personnel at all times. Prior

to operating the machine, you must have carefully read und understood

this operating manual. In case you do not understand this operating

manual or individual parts, please ask us prior to starting these activities.

The operating manual contains important information, which will ensure

that the machine can be operated in a safe, proper and economic

manner.

613-01

Foreword

Use

16

BA RD 24 US / RD 28 US en* 01*

1.02 Use

1.02.01 Intended use

The machine represents state-of-the-art technology and complies with

all valid safety regulations concerning its intended use at the time the

machine was launched on the market.

When designing the machine it was not possible to avoid forseeable

misuse or residual risks without restricting the machine's intended

functionality.

The maschine's intended use is:

pave roads and traffic areas.

ramming and smoothing of loose earth, road bedding, pavement or

similar ramable subgrade in layers.

The machine may only be deployed on surfaces that can support it.

Subgrade not capable of bearing is e.g. high fillings, batters, roadside

ditches.

The machine must not be used with explosive areas, on landfill sites and

with mining.

The machine is only intended for commercial applications within fenced

construction sites.

The machine must be operated by authorised operating personnel only if

in proper technical condition and according to this operating manual.

All unintended uses and/or all machine-related activities not described in

this operating manual are to be deemed as unauthorised misuse outside

the legal limits of indemnity of the manufacturer.

611-01

Foreword

Use

BA RD 24 US / RD 28 US en* 01*

17

1.02.02 Reasonably foreseeable misuse

In the case of reasonably foreseeable misuse and/or improper use of the

machine, the manufacturer's guarranty period will expire and the operator

will solely be responsible.

Reasonably foreseeable misuse is:

Non-compliance with this operating manual.

Operating errors by operating personnel not qualified or not

instructed.

Conveyance of passangers.

Leaving the driver's position during operation.

Starting, using the machine outside the driver's position.

Errors due to "reflexive behaviour" and/or "chosing the easiest way".

Operating the machine if it is not in a proper technical condition.

Using the machine with improper ambient conditions (e.g.

temperature, gradient, transverse gradient).

Using the machine with the protective equipment removed.

Spraying with high-pressure cleaners or fire extinguishing equipment.

Towing trailing loads.

Non-compliance with maintenance intervals.

Omission of measurements and tests to detect damages early.

Omission of replacing wear parts.

In the case the spare parts used are no original Wacker Neuson

spare parts.

Omission of maintenance and repair works.

Improper maintenance and repair works.

Unauthorised modifications of the machine.

611-05

1.02.03 Residual risks

Residual risks have been analysed and evaluated prior to starting the

construction and planning the machine. Existing residual risks are

referred to in the documentation. However, Wacker Neuson cannot

foresee all situations that may pose a risk in practice.

You can avoid existing residual risks if you comply with and

implement the following instructions:

Special warnings at the machine.

General safety instructions in this operating manual.

Special warnings in this operating manual.

Operating instructions of the operator.

Danger of life / risk of personal injury when operating the machine

due to:

Misuse.

Improper operation.

Transport.

Missing protective equipment.

Defective and/or damaged components.

Operation / usage by personnel not trained and/or instructed.

Foreword

Use

18

BA RD 24 US / RD 28 US en* 01*

The machine may cause risk to the environment with:

Improper operation.

Operating supply items (lubricants etc.).

Noise emission.

Property damage may occur at the machine e.g. with:

Improper operation.

Non-compliance with operating and maintenance instructions.

Improper operating supply items.

Property damage may occur at further assets within the

machine's operating area e.g. with:

Improper operation.

Reduction in performance and/or the machine's functionality may

occur at the machine with:

Improper operation.

Improper maintenance and/or repair works.

Improper operating supply items.

611-06

1.02.04 Climatic conditions

Low ambient temperature The diesel engine's starting behaviour and the machine's operation

depend on:

The fuel used.

The viscosity of the motor, gear and hydraulic oil.

The battery's charge state.

Please note:

The acceleration and braking behaviour of the machine are influenced by

viscous hydraulic oil. Prior to cold seasons (autumn, winter) please adjust

all operating supply items (coolants, oils etc.) to low temperatures.

Please use fuels suitable in winter or additives improving the flow with

temperatures below 0 °C (32 °F) (see page 131 sqq.). Do not charge

batteries with temperatures below 0 °C (32 °F) .

WARNING

Explosion!

Risk of injury due to burns and moving parts.

Do not use aerosol start-up aid (e.g. aether).

Do not use any liquids as start-up aid (e.g. alcohol).

002-02

Extensive ambient

temperature, extensive

height

See operating manual of diesel engine.

611-04

Foreword

Environmental protection

BA RD 24 US / RD 28 US en* 01*

19

1.03 Environmental protection

Packing materials, cleaning agents and used or residual operating supply

items are to be disposed according to relevant environmental provisions

at the building site using the recycling systems provided.

614-00

1.04 Disposal

Conservation of nature is one of our major tasks. Properly disposed

devices avoid negative impacts on human beings and the environment

and allows re-using our precious resources.

Operating supply items Please dispose all operating supply items according to relevant

specifications and local regulations of the relevant country.

Materials (metal, plastics) To be able to dispose materials professionally, these materials need to be

correctly sorted. Cleanse materials of adhesive impurities.

Please dispose all materials as demanded by local provisions of the

relevant country.

Electical / electronical

system / battery

Electrical / electronical components are not subject to

Directive 2002/96/EC and relevant national regulations (in Germany e.g.

ElektroG).

Dispose electrical / electronic components directly at a specialised

recycling company.

615-00

Foreword

Type plate

20

BA RD 24 US / RD 28 US en* 01*

1.05 Type plate

NOTE

For machines without EC Conformity, neither an EC

Declaration of Conformity nor a CE type plate can be issued.

This is the case if, for example, the machine does not have a

drum drive, drum brake or roll-over protection.

000-45

The entire marking represents an official document and must not be

altered or effaced.

NOTE

Please state the vehicle identification number (VIN) and the

type of your machine for every spare part order.

602-01

Machine type plate The type plate is fixed to the machine frame (see page 40).

NOTE

The VIN [E] indicates the type series and the serial number of

the machine e.g. WNCR0601JHAA00160.

The maximum operating weight [J] is the static weight of the

machine including:

Working substances and lubricants

100 % fuel tank contents x 0.84 specific weight

100 % water & additive tank contents

75 kg for the driver

the static weight of all options or attachments mountable at

the same time and approved by Wacker Neuson (e.g., chip

spreader).

No additional ballasting is allowed.

602-02

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